Introduction

A study was conducted for the improvement in structural design of a MMS Solar panel. Certain
failures were observed at site during installation. Based on the information collected from the site
failures a detailed study was conducted.

Background

During one of the site installation failures were observed which were critical in nature. The major task
was to improve design, keeping in mind the bulk of material which was already installed on site. The
new design was introduced which was a reinforcement on the existing installation so that there was
no requirement of dismantling the existing structure. The new design was numerically tested to
withstand the winds measuring the speeds of 150Kmph.

Site Findings

The site failures were observed and the evidences were collected which were required for improving
the design.

The failures were categorized as following

1> Failures in the structure. These were the failures which were due to the overloading of the
structure or under designing of the structure.

Exhibit 1. The self tapping screws give way and this leads to the bending of L plate and the
structure failure.

2> Failures in the foundation. These are the failures which were more concentrated on the
foundations and anchoring the structure.

Exhibit 2. The complete structure was tired from the roof slab. This can be due to under
designed anchor bolts.

3> Failure due to human failure. These failures were due to some human negligence or wrong
installation.
 Exhibit 3. The bolt was not tighten properly the slip caused the wring distribution of forces and
leads to the failure and undue bending of the plates.

Exhibit 4. The U Bolt was used to fix the pipe on the vertical structure. If due to some
negligence or vibrations the U bolt get loosen the complete structure can fail.

Working Methodology.

The complete study done can be concluded in the following stages.

1> Data collection. The data of the failure from site was collected and tabulated. The data such
as wind speed and fixing conditions were collected.
2> Creation of mission statement and the specification list. A detailed list of the specifications
and the requirements was created which helped us the validate the improved design.
3> Different concepts were formulated and discussed to find the most suited and feasible
solution.
4> Validation. The new design concept was validated using numerical methods (Finite Element
Analysis). The new design was validated against the specification list.
5> The validated design was used to create the detailed drawing for the site installation.

Design Validation.

Design was validated by using various numerical simulation techniques so as to get more accurate
results in as little time as possible. This was achieved in the following steps.

1> A 3D model of the existing structure was developed.

This 3D model was used for the simulation.

2> Numerical simulation.
 The complete structure was analysed using simulation software. The wind load and the self
weight were used as the loads for the simulation.

3> Improving the design.

 Based on the results from the first iteration the new design was developed.
4> Again the improved design was validated under the same loading condition and the results
were observed for the improvement.

Conclusion & Recommendation.

Following changes were recommended and considered.

1> The rows of the modules were connected to each other using angle of 40x40x5mm as shown
in the figure below.

2> Full weld around the plate (on all four sides) the welding can be done after bolting or without
bolting. The lower plate (shown in green color) should also be welded with the vertical
structure or should have at least two bolted connections. It is recommended to have weld at
this location.
3> Base plate which is welded to the vertical column shall be minimum 250 X 250 with two holes
placed diagonally.